Lincoln Electric IM305-C manual G1553

G1553
A
DIGITAL METER
VOLTMETER BOARD SPEED-
METER
BOARD
510
519
602
601
253 41
6
518
510
517
510P
602
601
510P
510P
602
601
510
510
519
510P
602
601
DIGITAL METER
253 41
6
WORK
WELDING
NOZZLE
ARM.
ELECTRODE
BLUE
BLACK
WHITE
RED
541
539
626
627
67
525A
555
510A
TACH.
PICK-UP
P.C. BD.
CONTROL
POWER
SOURCE
A
B
C
87
531
GND
A
B
C
D
E F
541
539
627
626
67
A
B
C
D
MOTOR RECEPTACLE
525A
555
510A
A
B
C
D
E F
TACH. RECEPTACLE
G
H
I
2
4
31
32
21
A
B
C
GREEN
531
87
FLUX OR WATER
SOLENOID
INPUT RECEPTACLE
S12778 S12515 S12514 S12515 S13161-052 S13161-5/64 S14904(OUTER) S14905(INNER) S12514 S14904(OUTER) S14905(INNER)
57F 57/1 57 57/1 95 95/1
95S 95/1
142 142/1
142/1
142T
SINGLE .035-.052 SINGLE 1/16-3/32
SINGLE 3/32-5/32
SINGLE 1/16-3/32 TWIN .045-.052 SINGLE 3/32-7/32
TWIN 3 32
/
TWIN 1/16-5/64
TWIN 5/64-1/8
40-778 I.P.M.
38-762 I.P.M.
22-428 I.P.M.
23-456 I.P.M. 15-289 I.P.M.
15-300 I.P.M.
PIN RATIO PART NUMBER RANGE RANGE
USE OF PIN "S" JUMPER CONNECTION.
541
539
627
87
32
531
532
531B
31
RF BYPASS
P.C. BOARD
62187
667 531626
WHITE
627
626
610
681
500
500
528
689
+
-
2 5
1
6
3 4
532
531A
631
610
531B 500
1/2A SLOW BLOW
POWER P. C. BOARD
POWER FUSE
1/2A SLOW BLOW
FIELD FUSE
539
627
541
626 1
2 3 4 5
6
528
500
CR4
COUPLED
MAGNETICALLY
ELECTRODE CABLE
TO POWER SOURCE
REED SWITCH ACTUATED BY
WELDING CURRENT
*
*
2
4
8
6
3 7
9
5
1
587
525
510
540
500
525
510
500
500
*
ORANGE
ORANGE
REDWHITERED
TS2
528
ELECT
67
TS1
500
WORK
21
531A
R1
631
531B
POLARITY CONNECTIONS WHICH MATCH ELECTRODE AND WORK CABLE POLARITY CONNECTIONS TO POWER SOURCE.
HI-FREQUENCY INSTALLATION INSTRUCTIONS FOR REQUIRED #67 ELECTRODE VOLTAGE SENSING LEAD CONNECTION.
NOTE: NA-5 MOTORS INSULATED FOR HIGH FREQUENCY STARTING DO NOT HAVE THIS CONNECTION. REFER TO
"COM" TAB, UNLESS SPECIFIED ON THE POWER SOURCE CONNECTION DIAGRAM TO BE CONNECTED TO THE "AUTO" TAB
TO DISABLE THE "COLD" STARTING FEATURE.
AND TAPED CONNECTION
532
531
531A
CB1
500
500
528
689
621
667
TERMINAL
STRIP JUMPER
CIRCUIT
POLARITY
TERMINALS
610 R
ELECTRODE
500
*
*
682
681
585
610
2
LOGIC
P.C. BOARD
*
*
BLUEBLUE
WHITE
RED
RED
BLUE
BLUE
YELLOW
YELLOW
BLACK
BLACK
601
602
T1
587
ORANGE
ORANGE
BROWN
BROWN
T2
500
12 540
10 525
9510
14
13 628
1520
8510P
7510P
METER
6632
2512
3511 5511A
4510P
15 586
11
*
CONTROL
P.C. BOARD
F
S
555510A525A
VOLTAGE P.C. BOARD
5169
514 2
635 4
564A
510P 8
10
5253
5107
500 6
5
5301
66711
62112
6
A
B4
C5
592 3
687 2
688 1
3
531B8
532 9
637 4
511 1
511A 2
7
500 6
5
*
FAST BLOW
FUSE
1 8 AMP
/
S
F
*
B
D
A
*
BYPASS COM
AUTO
*
4 2 13
688
688A
525
500
FILTER P.C. BOARD
LEAD PLUG
500
560 1
564 2
5003
5154
635 5
520 6
632 7
510P8
9
W
W10
564A11
12
*
PROCEDURE KIT
RECEPTACLE
JUMPER PLUG
ELECTRICAL SYMBOLS PER E1537
CAVITY NUMBERING SEQUENCE
*
N.M.
N.L.
N.E.
563
N.N.
1584C
2564
583S
4
5500
6515
3 500
1
5 4
6
3
589
5811
582 4
628 2
530 3
687 5
6886
5563
9563
6561
8560
7588
4584S 3566
2565
1583C
4
3
2
1
5
6
637
528
586
587
592
689
*
REMOTE INTERFACE
MODULE (OPTIONAL)
MOCMOCUP DOWN START STOP
SWITCHES
RED RED
N.L.
24V.
SIGNALS
*
1
6
5 4 2 3
581A
500
586
592
582
515
N.F.
WHITE
WHITE
RED
RED
N.D.
N.H
FLUX RECEPTACLE
J4
A
B
C
GND
D
532
25
531
J3
J2
J1
WORK CABLE TO
POWER SOURCE
TS
3
N.K.
N.J.
5A CIRCUIT
BREAKER
25
TRAVEL SW.
S2
532
531
31 32
POWER SW.
S1
"HOT" LIGHT
LT1
DOWN
592 500
S4
INCH UP
S3
586
500
625
N.A. SPEEDMETER BOARD CALIBRATION JUMPER IS TO BE CONNECTED FOR NA-5 HEAD AND DRIVE ROLL
EMPLOYED PER CHART BELOW: (CONNECTED TO PIN "95" OR "21" WHEN SHIPPED.
21 21/1 S12778 SINGLE .035-.052 100-2070 I.P.M.
= EARLIER SPEEDMETER BOARDS DID NOT HAVE THESE PINS. = SINGLE "21" PIN ON HIGH SPEED BOARD ONLY.
N.B. REMOVE START RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE
MODULE AS START PROCEDURE CONTROL. IF MODULE IS REMOVED, REPLACE JUMPER PLUG.
N.C. REMOVE CRATER RECEPTACLE JUMPER PLUG FROM PROCEDURE BOARD TO INSTALL OPTIONAL PROCEDURE
MODULE AS CRATER PROCEDURE CONTROL AND CONNECT LOGIC BOARD LEAD #694 TO PIN #P10.
IF MODULE IS REMOVED, REPLACE JUMPER PLUG AND LOGIC BOARD LEAD #694 TO PIN #P8.
N.D. CONTROL BOARD JUMPER LEAD CONNECTED TO PIN "F" WHEN SHIPPED. SEE OPERATING MANUAL FOR N.E. VOLTAGE BOARD RED JUMPER LEAD CONNECTED TO PIN "S" AND WHITE JUMPER LEAD CONNECTED TO
N.G. 531-532 115VAC
531-25 115VAC (SWITCHED) 250 VA
N.J. CONNECT #67 BLACK (ELECTRODE) LEAD AND #21 WHITE (WORK) LEAD TO APPROPRIATE TERMINAL STRIP N.K. LEAD CONNECTED TO MOTOR FRAME WHICH IS ELECTRICALLY COMMON WITH ELECTRODE DRIVE ROLL AND DRIVEN ELECTRODE.
N.L. REMOVE JUMPER PLUG TO INSTALL OPTIONAL KIT. IF KIT IS REMOVED, REPLACE JUMPER PLUG.
N.M. NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS.
N.N. BLUE JUMPER LEAD NOT PRESENT ON EARLIER VOLTAGE P.C. BOARDS. THE JUMPER IS TO BE CONNECTED TO THE
BLUE
WHITE
RED
582
STOP
S6
581A
682
ELECTRODE LEAD BOLTED
142T
95S 57F
TIMER BOARD
(START TIME USE)
655
500
I
O
515
12
4
14
13
9
6
7
1
8
10
11
3
5
2
15
500
510P
515
520
635
632
584S
583S
584C
583C
588
563
564
564A
START RECEPT. *
10
5
6
12
14
15
11
8
9
7
1
13
2
4
3520
515
510P
500
583S
584S
588
588A
635
632
655
JUMPER
PLUGS
{
{
*
10
5
6
12
14
15
11
8
9
7
1
13
2
4
3520
515
510P
500
588
588A
635
632
655
584C
583C
CRATER RECEPT.
OPTIONAL PROCEDURE MODULE
USED FOR START CONTROL
5
4
3
2
1
6
581A
581
565
566
561
560
*N.B.
N.C.
5
6
4
3
2
1
500
655
515
I
O
*
5 6
4
3 2
1
500 655 515
I
O
WELD TIME
RECEPT.
TIMER BOARD
655
500
I
O
515
OPTION BOARD
5
6
4
3
2
1
655
500
I
O
515
TIMER
RECEPT.
OPTIONAL PROCEDURE MODULE
USED FOR CRATER CONTROL
(CRATER TIME USE)
TIMER BOARD
(BURNBACK TIME)
500
655
515
I
O
START
S5
500
581A
581A
516
514
512
511
510P
601
602
517
519
655
500
I
O
515
WELD TIMER BOARD
(OPTIONAL)
N.A.
SET-ACTUAL
S7
PROCEDURE BOARD
*
BURNBACK
RECEPT.
531B 532
592
(COMPONENT SIDE OF P.C. BOARD)
SPEEDMETER NA-5 HEAD DRIVE ROLL WIRE SIZE RATED SPEED
562S
562S
562C
562C
142
95
57
1
2
3 4
1
2 3
4 5 6
1
2 3
4 5
6
7 8
9
1
2
3
4 5 6
7
8
9
10
11
12
1
2
3
4 5
6
7 8 9
10
11
12
13 14 15
12
6
1
J29
N.H. 531-87 115 VAC (SWITCHED) 1/2 AMP.
PIN "B" WHEN SHIPPED, FOR USE TYPICALLY WITH DC-[ ]TYPE POWER SOURCES. REFER TO CONNECTION DIAGRAM FOR ALTERNATE CONNECTIONS, AND JUMPER CONNECTIONS FOR R3S, SAM AND SAF OR SA POWER SOURCES WITH K224. EARLIER VOLTAGE BOARDS DO NOT CONTAIN PIN "D".
1/8 AMP FUSE
OPTIONAL PULSE POWER
TRAVEL RECEPT.
J5
1
562
583
655
515
500
584
588
588A
632
635
520
510P
9
10
8
3
2
6
4
12
5
11
*
7
P29 (C)
J29 (C)
J28 (C)
(CRATER FILL USE)
OPTION BOARD
5
6
4
3
2
1
655
500
I
O
515
TIMER
RECEPT.
1
562
583
655
515
500
584
588
588A
632
635
520
510P
9
10
8
3
2
6
4
12
5
11
*
7
(START USE)
J28 (S)
J29 (S)
P29 (S)
P28 (S)
3
1
J28
6
P28 (C)
CABLE
TO
532
87
610
532
585
589
FLUX RELAY MODULE
CR1
31
42
610
CR2
31
42
RELAY MODULE
RELAY MODULE
N.P.
532
TRAVEL
CONTACTOR
4
2
625
682
CR3
3
1
42
610
N.P.
N.P.
N.P. EARLIER RELAYS HAD SAME TERMINAL NUMBERS BUT IN A DIFFERENT ORIENTATION.
METHODS OF TRAVEL
START/STOP WITH SWITCHES
LEAD #691 to P6
LEAD #692 to P5
LEAD #691 to P6 LEAD #692 to P7
STOP WITH STOP SWITCH
LEAD #691 to P5 LEAD #692 to P7
START WITH START SWITCH STOP AFTER CRATER TIME
LEAD #691 to P6
LEAD #692 to P9 FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
CONNECT
CONNECT
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
FOR LOGIC P.C. BOARDS WITH
CONNECT CONNECT
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
FOR EARLIER LOGIC P.C. BOARDS WITH JUMPERS
YES CONNECT
LEAD #694 TO P10
NO CONNECT
LEAD #694 TO P8
CRATER BOARD INSTALLED?
SWITCH #1
1234
SWITCH #2
1234
SWITCH #1
1234
SWITCH #2
1234
FOR LOGIC P.C. BOARDS WITH DIP SWITCHES
DIP SWITCHES
FOR EARLIER LOGIC P.C.
BOARDS WITH JUMPERS
SWITCH #1
1 2 3 4
SWITCH #2
1234
SWITCH #1
1 2 3 4
SWITCH #2
1234
FOR LOGIC P.C. BOARDS WITH DIP SWITCHES
1 2 3 4 1 234
METHODS OF BURNBACK
CONNECT LEAD #690 TO P4 LEAD #693 TO P3 CONNECT LEAD #690 TO P4 LEAD #693 TO P1 CONNECT LEAD #690 TO P2 LEAD #693 TO P1
1 2 3 4
SAMPLE SWITCH
SWITCH POSITION 1 IS UP SWITCH POSITION 2 IS DOWN
SWITCH POSITIONS 3 AND 4 ARE NOT APPLICABLE
NA-5 SHIPPED CONNECTED FOR INDICATED METHODS OF TRAVEL & BURNBACK.
START WITH START SWITCH
LEAD #691 to P6
LEAD #692 to P8 CONNECT
SWITCH #1
1234
SWITCH #2
1234
START/STOP WITH WELD CURRENT START WITH WELD CURRENT (OPTIONAL PROCEDURE MODULE INSTALLED IN CRATER RECEPTACLE) (OPTIONAL PROCEDURE MODULE INSTALLED IN CRATER RECEPTACLE) STOP AFTER BURN-BACK TIME
N.F. LOGIC BOARD DIP SWITCHES OR JUMPERS TO BE SET TO SUIT DESIRED APPLICATIONS PER CHARTS BELOW:
WIRE FEED STOP WITH CONTACTOR DELAY INCH UP WITH CONTACTOR DELAY INCH UP WITH NO CONTACTOR DELAY
USE OF OPTIONAL CRATER MODULE
N.R.
N.R.
N.R.
N.R. POTENTIOMETERS AND SWITCHES MOUNTED ON P.C. BOARD ARE CONNECTED TO FRAME, FOR ESD.
(NOT PRESENT ON EARLIER BOARDS)
N.S. THE FIELD FUSE WAS REPLACED WITH A PTC RESETTABLE FUSE ON LATER MODEL POWER BOARDS.
N.S.